Method for manufacturing electronic parts module

ABSTRACT

The method for manufacturing an electronic parts module includes an adhesive layer forming process forming an adhesive layer including solder particles on the circuit forming surface in range covering at least the first land part and the second land part; a passive element mounting process positioning a terminal of the passive element on the first land part and sticking the passive element to the base wiring layer through the adhesive layer; an active element mounting process, after the passive element mounting process, positioning a terminal of the active element on the second land part and sticking the active element to the base wiring layer through the adhesive layer; a pressing process solidifying the adhesive layer and melting the solder particles by laminating and thermally pressing a thermosetting sheet onto the circuit forming surface so as to form the resin sealing layer.

BACKGROUND

The present invention relates to a method for manufacturing an electronic parts module that produces an electronic parts module having a structure in which electronic parts are mounted on a base wiring layer with a wiring pattern formed and the electronic parts and the wiring pattern are sealed by a sealing resin layer.

Electronic parts such as a semiconductor element are ordinarily incorporated in an electronic device in the form of an electronic parts module in which the electronic parts mounted on a base wiring layer such as a resin substrate are sealed by a resin. In accordance with a tendency that the high packaging density of the electronic parts module is required, as the electronic parts module, a form of what is called a parts incorporated printed wiring board is proposed in which the electronic parts are mounted on the inner layers of a plurality of laminated electrode patterns (for instance, JP-A-2007-88009). In an example disclosed in JP-A-2007-88009, an active element such as an IC chip and a passive element such as CR parts are mounted on the same base wiring layer.

However, when the active element and the passive element are mounted on the same base wiring layer, at the time of connecting these parts to the wiring layer, below-described difficulties arise. In mounting the electronic parts, a parts main body needs to be fixed to the base of the wiring layer and terminals of the parts need to be electrically connected to land parts of the wiring layer, however, the optimum connecting methods of the active element and the passive element are different from each other depending on their forms and characteristics. Therefore, when the parts are incorporated, it is necessary to individually mount the passive element and the active element. As a result, the manufacturing processes are complicated and therefore costly. The JP-A-2007-88009 discloses the example in which the active element and the passive element are mounted at the same time. However, in the JP-A-2007-88009, no concrete way how to connect the active element and the passive element to the wiring layer is disclosed. As described above, in the usual method for manufacturing a parts incorporated type electronic parts module, when the passive element and the active element are mounted on the same base wiring layer, the production process is complicated and the manufacturing cost is hardly reduced.

SUMMARY

Thus, it is an object of the present invention to provide a method for manufacturing an electronic parts module that can produce the electronic parts module having a structure that a passive element and an active element are mounted on the same base wiring layer by a simple production process.

The method for manufacturing an electronic parts module of the present invention is a method for manufacturing an electronic parts module includes a base wiring layer having a wiring pattern and a circuit forming surface, the wiring pattern formed on the circuit forming surface and including a first land part to which a passive element is connected and a second land part to which an active element is connected, and a resin sealing layer intimately formed on the circuit forming surface and sealing the passive element and the active element. The method includes an adhesive layer forming process forming an adhesive layer including solder particles on the circuit forming surface in range covering at least the first land part and the second land part, a passive element mounting process positioning a terminal of the passive element on the first land part and sticking the passive element to the base wiring layer through the adhesive layer, an active element mounting process, after the passive element mounting process, positioning a terminal of the active element on the second land part and sticking the active element to the base wiring layer through the adhesive layer, a pressing process solidifying the adhesive layer and melting the solder particles by laminating and thermally pressing a thermosetting sheet onto the circuit forming surface so as to form the resin sealing layer.

According to the present invention, when the electronic parts module includes the passive element and the active element mounted on the same base wiring layer is produced, the production processes are employed in which the adhesive layer including the solder particles is formed on the circuit forming surface of the base wiring layer, after the passive element is previously mounted on the base wiring layer, the active element is mounted on the base wiring layer and stuck to the base wiring layer by the adhesive layer, and then, the thermosetting sheet for forming the sealing resin layer is laminated to the circuit forming surface to which the passive element and the active element are stuck and thermally pressed to solidify the adhesive layer and melt the solder particles included in the adhesive layer at the same time. Thus, the electronic parts module having the structure that the passive element and the active element are mounted on the same base wiring layer can be produced by the simple production processes.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A to 1D are process explanatory views showing a method for producing an electronic parts module of one embodiment of the present invention.

FIGS. 2A to 2C are process explanatory views showing the method for producing the electronic parts module of the one embodiment of the present invention.

FIGS. 3A and 3B is structure explanatory views of a passive element and an active element mounted on the electronic parts module of the one embodiment of the present invention.

FIGS. 4A to 4B are explanatory views of connecting states of the passive element and the active element in the electronic parts module of the one embodiment of the present invention.

PREFERRED EMBODIMENT

Now, an embodiment of the present invention will be described by referring to the drawings. FIGS. 1A to 1D and FIGS. 2A to 2C are explanatory views showing a method for manufacturing an electronic parts module of one embodiment of the present invention. FIGS. 3A and 3B is an explanatory view of structures of a passive element and an active element mounted on the electronic parts module of the one embodiment of the present invention. FIG. 4 is an explanatory view of connecting states of the passive element and the active element in the electronic parts module of the one embodiment of the present invention.

Initially, a method for manufacturing the electronic parts module will be described. FIGS. 1A to 1D and FIGS. 2A to 2C show the method for manufacturing the electronic parts module in order of processes, which is formed by mounting the passive element represented by CR parts (FIG. 3B) such as a capacitor, a resistance, etc. and the active element such as an IC chip (FIG. 3A) with a bump on the same base wiring layer having a wiring pattern formed on a circuit forming surface.

FIG. 1A shows a base wiring layer 1 serving as a base part of the electronic parts module. On a circuit forming surface 2 a in an upper surface side of a resin substrate 2 forming the base wiring layer 1, a wiring pattern having a first land part 3 and a second land part 4 is formed. The electronic parts module is configured that the passive element and the active element are sealed by a sealing resin layer (see a sealing resin layer 13A shown in FIG. 2C) under the condition that a terminal of the passive element is electrically connected to the first land part 3 and a terminal of the active element is electrically connected to the second land part 4 respectively.

Then, an adhesive layer for connecting parts is formed on the circuit forming surface 2 a of the resin substrate 2. Namely, as shown in FIG. 1B, a liquid resin adhesive 5 is provided in ranges that cover the first land part 3 and the second land part 4 on the circuit forming surface 2 a by a method of a screen printing or an application by a dispenser. The resin adhesive 5 is a thermosetting resin 6 including solder particles 7. The thermosetting resin 6 is a liquid adhesive which has an activation effect removing an oxide layer of a solder. As the solder particles 7, for instance, the solder particles having a composition of SnBi58 and a melting point temperature of about 139° C. are used. As the thermosetting resin 6, for instance, an epoxy resin, an acrylate resin, polyimide, polyurethane and phenol resins, and an unsaturated polyester resin are employed.

After that, the base wiring layer 1 on which the resin adhesive 5 is arranged is transferred to a curing device and heated under a prescribed heating condition. Thus, the thermosetting reaction of the thermosetting resin 6 in the resin adhesive 5 arranged on the circuit forming surface 2 a progresses. At this time, the thermosetting resin 6 is not completely solidified by controlling a heating to stop the thermosetting reaction halfway. Thus, the thermosetting resin 6 becomes a thermosetting resin 6A in a gel state so that a semi-solidified adhesive layer 5A is formed. The aim of the semi-solidification of the thermosetting resin 6 is increasing an adhesive power of the resin adhesive 5 and stably holding the parts such as passive elements and active elements on the base wiring layer 1 during parts mounting process in a post process. Here, on the circuit forming surface 2 a, the adhesive layers are formed only in the ranges that cover the first land part 3 and the second land part 4. It is to be understood that the adhesive layer SA may be formed in all the range of the circuit forming surface 2 a, however, the adhesive layer is desirably limited to the ranges that cover at least the first land part 3 and the second land part 4 in view of saving resources and reducing a cost.

Namely, a process illustrated in FIGS. 1B and 1C shows an adhesive layer forming process that forms the adhesive layer 5A including the solder particles 7 in the ranges that cover at least the first land part 3 and the second land part 4 on the upper surface of the base wiring layer 1. Further, in an example shown in this embodiment, the adhesive layer forming process includes an adhesive arranging process (FIG. 1B) that arranges the liquid adhesive 5 having the solder particles 7 at least on the first land part 3 and the second land part 4 and a semi-solidifying or a half solidifying process (FIG. 1C) that semi-solidifies or half solidifies the arranged adhesive 5.

In stead of the process forming the adhesive layer by semi-solidification of the liquid resin adhesive 5 after arranging the liquid resin adhesive 5 on the circuit forming surface 2 a, a sheet like adhesive which is formed from the thermosetting resin 6 including the solder particles 7 by semi-solidification may be used.

In this case, the sheet type adhesive of a size corresponding to that of the adhesive layer 5A formed in FIG. 1C) is prepared, laminated to and arranged on the circuit forming surface 2 a, so that the adhesive layer similar to the adhesive layer 5A is formed. That is, in this example, the sheet type adhesive including the solder particles is arranged at least on the first land part 3 and the second land part 4 in the adhesive layer forming process.

Then, the parts are mounted on the base wiring layer. In mounting the parts, an IC chip 8 having bumps and CR parts 9 such as a capacitor, a resistance, etc. shown in FIG. 3 are mounted on the resin substrate 2. The IC chip 8 is the active element and a plurality of metal bumps 8 a as terminals for connection are formed on a lower surface of the IC chip 8. The arrangement of the second land parts 4 in the resin substrate 2 corresponds to the arrangement of the metal bumps 8 a in the IC chip 8. The metal bump 8 a may be formed with a solder or other metals. In either case, a melting point of the metal bump 8 a is higher than a heating temperature of a below-described pressing process. The CR part 9 is the passive element and has terminal electrodes 9 a as terminals for connection formed at both ends.

In this embodiment, the CR parts 9 as the passive element is initially mounted on the base wiring layer. That is, as shown in FIG. 1D, the CR parts 9 is held by an adsorption nozzle 10 and the terminal electrodes 9 a of the CR parts 9 are positioned to the land parts 3 to mount the CR parts 9 on the base wiring layer 1 and stick the CR parts 9 thereto through the adhesive layer 5A (a passive element mounting process). Then, the IC chip 8 as the active element is mounted on the base wiring layer 1. That is, after the passive element mounting process, the metal bumps 8 a of the IC chip 8 are positioned to the second land parts 4 to mount the IC chip 8 on the base wiring layer 1 and stick the IC chip 8 thereto through the adhesive layer 5A (an active element mounting process). Thus, the CR parts 9 and the IC chip 8 are respectively held by the first land parts 3 and the second land parts 4 of the base wiring layer 1 by an adhesive power of the adhesive layer 5A in the semi-solidified state.

Further, in this embodiment, as shown in FIG. 2A, in the active element mounting process, a thermally pressing tool 11 is used. Namely, the IC chip 8 held by the thermally pressing tool 11 is pressed to the base wiring layer 1 by pressing the metal bumps 8 a to the second land parts 4 and melting the solder particles 7 in the adhesive layer 5A in contact with the metal bumps 8 a by heating the IC chip 8 through the thermally pressing tool 11. Thus, a large quantity of the solder is allowed to be laminated to the metal bumps 8 a as much as possible before a connection by the solder in the below-described pressing process, so that a reliability of the connection can be improved.

At this time, the process conditions are set so that pressurizing and heating operations by the thermally pressing tool 11 are released while the thermosetting resin 6A forming the adhesive layer 5A is still semi-solidified. Thus, in the below-described pressing process in a post-process, when the solder particles 7 in the adhesive layer 5A are molten to connect the metal bumps 8 a to the second land parts 4 by the solder, the thermosetting resin 6A still maintains its semi-solidified state and the fluidity of the molten solder in which the solder particles 7 are molten is not prevented by the thermosetting resin 6A. Accordingly, an inconvenience can be prevented such as an inferior form of a solder connection part due to restriction of the fluidity of the molten solder by the already solidified thermosetting resin.

In the example shown in this embodiment, in the active element mounting process, the thermosetting reaction of the thermosetting resin 6A is accelerated and the solder elements 7 are partly molten by using the thermally pressing tool 11 before the pressing process, however, these operations are not necessarily essential processes. Namely, in the active element mounting process, in addition to pressing the metal bump 8 a onto the land parts 4, heating to promote thermosetting reaction of the thermosetting resin 6A without melting the solder particles 7 may be performed. Specifically, a heating condition by the thermally pressing tool 11 is set to a heating operation of a temperature at which the solder particles 7 are not molten to accelerate only the thermosetting reaction of the thermosetting resin 6A. Also in this case, as described above, the process conditions are set so that pressurizing and heating operations by the thermally pressing tool 11 are released while the thermosetting resin 6A is still semi-solidified. Further, in the active element mounting process, the metal bumps 8 a may be merely positioned to the second land parts 4 and pressed thereto, and the IC chip 8 may not be heated. In this case, the thermosetting reaction of the thermosetting resin 6A in a semi-solidified state is completed and the solder particles 7 are molten to carry out the connection by the solder by a heating operation in the pressing process as the post-process.

After that, the base wiring layer 1 is transferred to the pressing process. In the pressing process, as shown in FIG. 2B, a thermosetting sheet 12 is laminated to the base wiring layer 1 and thermally pressed by a pressing device having a heater. The thermosetting sheet 12 has a structure that a copper film 14 is laminated to a prepreg 13. In this thermally pressing process, the thermosetting sheet 12 is pressurized under a pressure of about 30 kg/cm² by the pressing device and heated at a temperature of about 150° C. to 200° C. The heating temperature at this time is set so as to be higher than the melting point temperature of the solder particles 7 in the adhesive layer 5A. A resin with which the prepreg 13 is impregnated is temporarily softened and flows by the heating operation so as to enclose the IC chip 8 or the CR parts 9 from their peripheries. The pressurizing and heating operations are continuously carried out for a prescribed time to thermally solidify the prepreg 13 as shown in FIG. 2C, so that a sealing resin layer 13A is formed that seals the IC chip 8 or the CR parts 9 on the circuit forming surface 2 a of the resin substrate 2.

In the pressurizing and heating operations, the solder particles 7 molten in the vicinity of the metal bumps 8 a of the IC chip 8 in the adhesive layer 5A that covers the second land parts 4 wet the second land parts 4 and the metal bumps 8 a and coagulate. These molten solder particles are cooled and solidified to form solder connecting parts 7A for connecting the second land parts 4 to the metal bumps 8 a as shown in FIG. 4A. Further, the thermosetting reaction of the thermosetting resin 6A of the adhesive layer 5A in the semi-solidified state is further advanced by the heating operation so that a resin reinforcing part 5B is formed for enclosing and reinforcing the solder connecting parts 7A of the metal bumps 8 a and the second land parts 4 from their peripheries. Further, in the CR parts 9, the solder particles 7 molten in the vicinity of the terminal electrodes 9 a of the CR parts 9 in the adhesive layer 5A that covers the first land parts 3 wet the first land parts 3 and the terminal electrodes 9 a and coagulate in the fillet forms. These molten solder particles are cooled and solidified to form solder connecting parts 7A for connecting the first land parts 3 to the terminal electrodes 9 a as shown in FIG. 4B. Further, the thermosetting reaction of the thermosetting resin 6A of the adhesive layer 5A in the semi-solidified state is further advanced by the heating operation so that a resin reinforcing part 5B is formed for covering and reinforcing the solder connecting parts 7A of the terminal electrodes 9 a and the first land parts 3.

Namely, in the above-described pressing process, the thermosetting sheet 12 is laminated and thermally pressed on the circuit forming surface 2 a of the resin substrate 2 of the base wiring layer 1 on which the IC chip 8 and the CR parts 9 adhere. The thermosetting sheet 12 forms the sealing resin layer which seals the IC chip 8 and the CR parts 9 on the circuit forming surface 2 a of the resin substrate 2 of the base wiring layer 1. Thus, the adhesive layer 5A is solidified and the solder particles 7 included in the adhesive layer 5A are molten at the same, so that the above-described solder connecting parts 7A and the resin reinforcing part 5B are formed.

Thus, the electronic parts module 15 is completed in which the terminal electrodes 9 a of the CR parts 9 are electrically connected to the first land parts 3 and the metal bumps 8 a of the IC chip 8 are electrically connected to the second land parts 4 respectively and the CR parts 9 and the IC chip 8 are respectively mounted on the base wiring layer 1 on which a wiring pattern is formed that includes the first land parts 3 for connecting the CR parts 9 and the second land parts 4 for connecting the IC chip 8 to the circuit forming surface 2 a, and the CR parts 9 and the IC chip 8 are sealed by the sealing resin layer 13A formed so as to come into close contact with the circuit forming surface 2 a.

As described above, in the method for producing the electronic parts module 15 shown in the embodiment, when the electronic parts module 15 is produced that includes the CR parts 9 as the passive element and the IC chip 8 as the active element mounted on the same base wiring layer 1, production processes are employed in which the adhesive layer 5A including the solder particles 7 is formed on the circuit forming surface 2 a of the base wiring layer 1, the CR parts 9 is previously mounted on the base wiring layer 1, then, the IC chip 8 is mounted on the base wiring layer 1 and stuck to the base wiring layer 1 by the adhesive layer 5A, and then, the thermosetting sheet 12 for forming the sealing resin layer is laminated to the circuit forming surface 2 a of the base wiring layer 1 to which the CR parts 9 and the IC chip 8 are stuck and thermally pressed to solidify the adhesive layer 5A and melt the solder particles 7 included in the adhesive layer 5A at the same time. Thus, the electronic parts module having the structure that the passive element and the active element are mounted on the same base wiring layer can be produced by the simple production processes.

In the structure that the passive element and the active element are mounted on the same base wiring layer 1 as in this embodiment, since processes for mounting the passive element and the active element or tools employed for mounting the passive element and the active element are different from each other, it is necessary to determine which of the passive element and the active element is to be previously mounted. In this embodiment, as described above, an order of processes is that the passive element is mounted on the base wiring layer before the active element is mounted. Thus, an inconvenience occurring when the active element is previously mounted on the base wiring layer can be avoided.

Namely, when the active element is previously mounted on the base wiring layer, a fragile thin active element such as a flip chip which is mounted in advance may be broken or displaced due to mounting of the passive element performed after the active element mounting. Further, when the active element is mounted on the base wiring layer, the heating operation is desirably carried out by the thermally pressing tool. However, when the active element is previously mounted on the base wiring layer, the preliminary supplied adhesive layer for the passive element is solidified or flows due to the influence of heat caused from the heating operation. As compared therewith, as shown in this embodiment, the passive element is previously mounted on the base wiring layer before the active element, so that the above-described inconveniences can be prevented.

The method for producing the electronic parts module of the present invention can advantageously produce the electronic parts module having the structure that the passive element and the active element are mounted on the same base wiring layer by the simple production processes and is useful for a production field of an electronic parts module formed by laminating a plurality of wiring layers. 

1. A method for manufacturing an electronic parts module, the electronic parts module comprising a base wiring layer having a wiring pattern and a circuit forming surface, the wiring pattern formed on the circuit forming surface and including a first land part to which a passive element is connected and a second land part to which an active element is connected; and a resin sealing layer intimately formed on the circuit forming surface and sealing the passive element and the active element, comprising: an adhesive layer forming process forming an adhesive layer including solder particles on the circuit forming surface in range covering at least the first land part and the second land part; a passive element mounting process positioning a terminal of the passive element on the first land part and sticking the passive element to the base wiring layer through the adhesive layer; an active element mounting process, after the passive element mounting process, positioning a terminal of the active element on the second land part and sticking the active element to the base wiring layer through the adhesive layer; a pressing process solidifying the adhesive layer and melting the solder particles by laminating and thermally pressing a thermosetting sheet onto the circuit forming surface so as to form the resin sealing layer.
 2. The method according to claim 1, wherein the adhesive layer forming process includes steps of: arranging liquid adhesive including the solder particles on at least the first land part and the second land part, and semi-solidifying the arranged liquid adhesive.
 3. The method according to claim 1, wherein the adhesive layer forming process includes a step of: arranging a sheet type adhesive including solder particles on at least the first land part and the second land part.
 4. The method according to claim 1, wherein the active element mounting process including steps of: heating the active element and pressing the active element onto the base wiring layer by a thermally pressing tool and melting the solder particles in the vicinity of the terminal of the active element; releasing the heating and pressing by the thermally pressing tool while the adhesive layer is semi-solidified.
 5. The method according to claim 2, wherein the active element mounting process including steps of: heating the active element and pressing the active element onto the base wiring layer by a thermally pressing tool and melting the solder particles in the vicinity of the terminal of the active element; releasing the heating and pressing by the thermally pressing tool while the adhesive layer is semi-solidified.
 6. The method according to claim 3, wherein the active element mounting process including steps of: heating the active element and pressing the active element onto the base wiring layer by a thermally pressing tool and melting the solder particles in the vicinity of the terminal of the active element; releasing the heating and pressing by the thermally pressing tool while the adhesive layer is semi-solidified.
 7. The method according to claim 1, wherein the solidification of the adhesive layer and melting of the solder particles are performed at the same time. 